Hyundai Motor upgrades India plant with robots, AI technology

By Maekyung News Service

South Korean auto giant Hyundai Motor Co. has transformed its Pune plant in India into a smart factory, expanding its robot fleet from six to 204 and fully automating welding to produce a car body every two minutes.

During a visit to the plant on Wednesday, local time, by Maeil Business, robots were seen welding body frames and lifting components for assembly before sending the finished bodies to the paint shop. The production line is enclosed by transparent barriers to restrict human access.

Welding and painting are both fully automated, with no manual intervention in the welding process.

“Labor costs are low in India, but automation is essential to ensure quality,” said Lee Doo-hyung, an official from Hyundai Motor. “Manual welding and painting inevitably involve some margin of error.”

Acquired from General Motors Co. in 2023, the Maharashtra facility has adopted advanced automation and artificial intelligence (AI) technologies to improve production efficiency, safety, and quality.

AI cameras monitor workers near press machinery, while automated inspection systems detect cracks and surface defects during stamping and painting. Smart tags and augmented reality training also help prevent assembly errors and improve worker skills.

The plant is preparing to manufacture hybrid and larger vehicles for the Indian market.

Tarun Garg, managing director and chief executive officer (CEO) of Hyundai Motor India, said that the plant will serve as an excellent hub for hybrid vehicle production. “Its high level of automation would significantly strengthen our manufacturing capabilities.”

Hyundai Motor Group plans to invest about $15.5 billion in India by 2032, coinciding with the inauguration of the upgraded Pune plant.

At the inauguration ceremony, Hyundai Motor Group Vice Chairman Chang Jae-hoon said about 60 percent of the investment would go toward upgrading aging facilities and expanding capacity where production capabilities are insufficient.

The conglomerate also plans to establish HMG India, a group-level entity specializing in investment to coordinate projects spanning not only automobiles and mobility but also energy and AI. The new entity will also handle government relations and public relations activities, Chang said.

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